Foam Cosplay Horns

This is a headdress for a Satyr costume that I made for a themed party.

This step-by-step focuses on the horns only.

Glue gun, craft scissors, sharpie, pen, foam sheet, contact cement, brush, aluminum foil, painter's tape, mod podge, origami paper, artificial flowers, wire, and headband.

Sculpt a horn out of aluminum foil. Shape it so that it has a triangular cross-section because that is where you'll cut the seams for your template.

Cover the foil in painter's tape. Put a few layers down so that it holds together when you cut the seams.

Cut the painter's tape at the seams. Carefully remove it from the foil and stick it to a sheet of printer paper. Voila! Here is your template. If you want to skip making a template, you can use one of the ones provided.

Trace your template on a sheet of foam twice because you'll want two horns. Cut it out and then label the inside of each piece so that you know which is which. To get the mirror image for the other horn, be sure to flip one set of pieces over.

To make more surface area for the glue to adhere to and to make the pieces fit together more accurately, trim around each edge on the inside face. Trim off a small 45-degree triangle of foam, being careful not to cut through the side that will become the outside face. Apply contact cement to all the edges and wait ten minutes for it to dry.

Starting at the tips, glue the horns together. There may be some trimming and adjusting to do at the end.

Special thanks to Mannequin Madness for their excellent headdress workshop! https://www.mannequinmadness.com/pages/the-headdress-work-shop

These horns were finished with decoupage. I coated them with mod podge and then glued origami paper strips to them. They could also be painted or finished in any number of ways. Happy making!